Disposable absorbent garment such as a diaper or training pants and a process of making the same

ABSTRACT

A disposable absorbent garment includes a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The topsheet, the backsheet, and the absorbent core form a layered assembly including a front region, a back region, and a crotch region disposed between the front region and the back region. The garment is characterized by a vertical longitudinal plane that extends substantially centrally through the front, back and crotch regions. Each of the front and back regions includes a pair of ear portions extending in substantially opposite lateral directions with respect to the longitudinal plane. Each ear portion is a breathable stretchable layer assembly having a plurality of vent sites. Further, each ear portion includes an outer layer that is an extension of the backsheet and which extends laterally to the side edge of the ear portion, and an inner layer that is an extension of the topsheet and which also extends laterally to the side edge of the ear portion. The ear portion also includes a stretchable material layer secured between the inner layer and the outer layer. The topsheet includes a central section that is generally disposed in a center section of the garment and over the core. Each of a pair of side sections of the topsheet extends laterally and forms the inner layer of two of the ear portions. The side section also forms an outer wall section of a leg cuff that extends longitudinally along the lateral side of the core. An inner wall section of the leg cuff is a portion of a substantially impervious material that extends below the leg cuff to sealingly engage the side edge of a polymeric film barrier disposed underneath the core. The substantially impervious material and the polymeric film barrier combine to form a substantially impervious containment structure about the sides and bottom of the core.

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to a disposable absorbentgarment and a process of making the same.

[0002] Disposable absorbent garments contemplated by the inventioninclude disposable diapers, disposable pull-on garments, and the like.These garments are worn about the lower torso or waist of the user so asto receive and contain urine and other bodily wastes. Disposable diapersare particularly intended for use on infants who depend on a caretakerto fit the diaper. Typically, the infant is laid down while thecaretaker places the garment around the waist region of the infant andthen secures two ends on each side of the diaper together.

[0003] Disposable pull-on garments include training pants, pull-ondiapers, disposable underwear, and adult incontinence garments. It isgenerally expected that the user of any one of these garments will beable to put on and take off the garment on his/her own. As for trainingpants, these garments are intended for use on a young child just beforeor about the time the child is ready to graduate from diapers to regularunderpants (i.e., during toilet training). Training pants (and otherdisposable pull-on pants) have closed sides such that the user or caregiver raises the garment about the user's legs to put it on and slipsthe garment downward about the user's legs to take it off. Thus,training pants (and other pull-on pants) are designed to be put on andtaken off in the same manner by which regular underpants are put on andtaken off. This feature is particularly advantageous in toilet trainingbecause it provides an early introduction to underpants and, morespecifically, trains the child to wear regular underpants. Similarly, itis advantageous that the training pants fit and look very much likeregular underpants so that the child is comfortable in making thetransition from training pants to regular underpants.

[0004] The principal elements that typically make up the disposableabsorbent garments described above are a liquid-permeable inner layer(or topsheet), a liquid-impermeable outer layer (or backsheet) and anabsorbent core sandwiched between the inner and outer layers. Elasticmembers may also be incorporated into different parts of the garments.For example, elastic members may be positioned longitudinally along thediaper, generally outboard of the absorbent core to effect a seal aroundthe buttocks, legs or both of the user. In addition, several elasticmembers (e.g., in the form of elongated elastic threads) may bepositioned laterally throughout the waist region (including the sidewaist regions) of a disposable absorbent garment to allow the garment tostretch when it is put on and then during wear. In this way, the garmentcan stretch to accommodate variations in waist size and leg size of theuser, while fitting snugly about the waist and legs and without sagging.One drawback, however, is that the elastic strands are visible on theouter surfaces of the garment and can interfere to some extent withdecorative or instructional printing displayed on the outer surfaces ofthe garment.

[0005] Despite the increasing acceptance of disposable garments over thetraditional cloth diapers, environmental concerns remain. A closelyrelated issue is “source reduction” as it relates to conservation ofresources. Accordingly, products which require fewer materials toaccomplish the same functionality are particularly desirable.

[0006] Moreover, due to the high frequency of use and inherent“disposability” of disposable garments, consumers are very sensitive tothe price they pay for the garments. Therefore, it is desirable formanufacturers to provide a more cost-effective disposable absorbentgarment.

[0007] It is also known to provide disposable garments with separateside waist regions in the form of elastic side panels such as thosedisclosed in U.S. Pat. No. 4,938,753. The elastic side panels describedtherein have side edges, which are attached to the outer edges of acentral absorbent core assembly. The elastic side panels may be madefrom various elastomeric materials or combinations thereof and provide amore uniform fit generally more snug than side waist regions havingelongated elastic strands. Moreover, the elastic side panels provideouter surfaces, which are more uniform than the outer surfaces on sidewaist regions having elongated elastic strands. However, the elastomericmaterial for the side panel does not typically provide for a smooth,even outer surface when the side panels are in either the relaxed stateor the stretched state. Accordingly, the side panels are notparticularly conducive to having decorative or instructional printingdisplayed thereon. In addition, the cost of producing separate sidepanel products is high due to the nature of the materials and theprocess difficulties of handing multiple web components. Again, the costis critical to users of disposable garments due to their high rate ofuse. Furthermore, the separate side panel construction inherently relieson additional seams which detract from the product's appearance, makingthe product look less like real underwear.

[0008] Alternatively, it is known to provide a unitary pair of trainingpants with elasticized ear flaps such as those disclosed in U.S. Pat.No. 5,246,433. The elasticized ear flaps are formed by sandwiching arelaxed elastomeric element between two material layers of the earflaps, and adhesively attaching the material layers to the relaxedelastomeric element to form an elastic laminate. The design also callsfor mechanically stretching the elastic laminate such that the materiallayers permanently deform. Although the side waist region according tothis design generally provides a more uniform fit than a side waistregion having elongated elastic strands, the outside surfaces of theside waist region are not conducive to having decorative orinstructional print displayed thereon because the mechanically stretchedmaterial layers are uneven and cannot fully return to their originalundistorted configuration. Other drawbacks of this and related designsinclude: 1) poor appearance due to deformation of materials, 2) limitedrange of stretch, and 3) loss of integrity of the inner and outerlayers, weakening the product and forcing the use of higher strength andhigher cost elastomers.

SUMMARY OF THE INVENTION

[0009] It is, therefore, one object of the invention to provide animproved disposable absorbent garment such as a diaper or adultincontinence garment, and an improved method of making such a garmentand/or components of the garment.

[0010] In accordance with one aspect of the present invention, adisposable absorbent garment is provided having a topsheet, a backsheet,and an absorbent core disposed between the topsheet and the backsheet.The topsheet, backsheet, and core together form a front region, a backregion, and a crotch region disposed between the front region and theback region. To facilitate reference, the garment may be described ashaving a vertical longitudinal plane that extends substantiallycentrally through the front, back and crotch regions.

[0011] Preferably each of the front and back regions includes a pair ofear portions which, extend in substantially opposite lateral directionswith respect to the longitudinal plane. Each ear portion is abreathable, stretchable layer assembly. Preferably, this stretchablelayer assembly includes a plurality of breathing or vent sites which arespaced from one another to present a staggered pattern of vent sites onthe ear portions. At the vent sites, an outer material layer of the earportion (e.g., an extension of the backsheet) is bonded with an innermaterial layer of the ear portion (e.g., an extension of the topsheet).As a result of a bonding process, such as ultrasonic bonding, vent sitesare created which include a hole(s) or aperture(s) through thestretchable material layer (and through the inner material layer and theouter material layer) and through which air is passable. The presentinvention is also directed to a method of making an ear region, sidewaist region or side panel having such breathable attributes and,alternatively, a method for making a composite web structure or garmenthaving such breathable attributes.

[0012] In accordance with another aspect of the invention, a disposableabsorbent garment is provided having a topsheet, a backsheet, and anabsorbent core disposed between the topsheet and the backsheet. Thetopsheet, backsheet, and absorbent core form a front region, a backregion, and a crotch region disposed between the front region and backregions. Further, each of the front and back regions includes a pair ofear portions extending in substantially opposite lateral directions.Each ear portion has a stretchable layer assembly of an outer materiallayer, an inner material layer, and a stretchable member or materiallayer secured therebetween. The outer material layer is an extension ofthe backsheet and extends laterally to form, at least partially, a sideedge of the ear portion (i.e., side edge of the garment). Similarly, theinner material layer is an extension of the topsheet and extendslaterally to also form, at least partially, a side edge of the earportion. Accordingly, an ear portion may be formed that is seamless(i.e., along the outer and inner surfaces) as well as stretchable.

[0013] Preferably, the topsheet is a three-piece topsheet assemblyconsisting of a central section (including a portion generally disposedover the core) and a pair of side or outer sections which form orprovide the inner material layers of two of the ear portions (e.g., forthe two ear portions or the two right ear portions). Moreover, thegarment may include a longitudinally-extending, preferably elasticized,leg cuff spaced in generally parallel relation from each lateral side ofthe core. The leg cuff may include an outer material, section or layerthat is formed from the topsheet (e.g., topsheet side or outer section)and an inner material, section or layer that is substantiallyimpervious.

[0014] Further yet, the stretchable material layer may be one that isextendible between a contracted configuration and an extendedconfiguration and is preferably secured to the outer material layer whenthe stretchable material layer is disposed in the extendedconfiguration. As a result, the outer material layer is subsequentlycontractible then extendible with the stretchable material layer (and,more particularly, its outer surface is returnable to a substantiallysmooth and planar configuration).

[0015] The invention, therefore, provides a garment with stretchable earportions that employ a relatively few number of materials and componentsthan is typical and are less expensive to produce. Such attributes areparticularly important in products such as diapers and training pantswhich are consumed by users at a high rate. As compared to prior artproducts with side panels, the present invention provides a garment withstretchable ear portions or layers which can be (but not necessarily)seamless and thus, have a more desirable appearance, employ fewercomponents, and are relatively easy to construct. As a result, theseinventive garments may be made so as to be relatively less costly andmore comfortable to wear. Further, the inventive garment may berelatively lighter than prior art garments, and thus more comfortable towear.

[0016] In accordance with another aspect of the present invention, adisposable absorbent garment is provided having a topsheet, a backsheet,and an absorbent core disposed between the topsheet and the backsheet.The topsheet, backsheet, and the absorbent core also form a frontregion, a back region, and a crotch region disposed between the frontand back regions. Each of the front and back regions includes a pair ofear portions extending in substantially opposite lateral directions. Thegarment further includes a longitudinally extending leg cuff spaced, ingenerally parallel relation, from each lateral side of the core. The legcuff has a first layer formed from a substantially impervious material(e.g., preferably a hydrophobic material such as a polymeric material)and a second layer formed from the topsheet. It is to be understood thatthe first and second layers of the leg cuff may also be referred to ascuff sections, cuff material or surface, cuff wall and like structure.

[0017] For purposes of the present descriptions of the invention, theterm “impervious” means impervious to liquid passage. Also, the term“breathable structure” means a structure that substantially allows airto pass therethrough.

[0018] In accordance with yet another aspect of the present invention, adisposable absorbent garment is provided having a topsheet, a backsheet,an absorbent core disposed between the topsheet and backsheet, and apolymeric layer (e.g., sheet or mask or film applied onto the backsheet)disposed adjacent the backsheet and generally beneath the core. Thesecomponents form a garment having a front region, a back region, and acrotch region disposed between the front region and the back region, anda longitudinal plane that extends substantially centrally through thefront, back, and crotch regions. Further, each of the front and backregions includes a pair of ear portions extending in substantiallyopposite lateral directions with respect to the longitudinal plane. Thegarment also includes a pair of longitudinally extending leg cuffs,wherein each leg cuff is spaced from a lateral side of the core. Furtheryet, the garment includes a substantially impervious containmentstructure or barrier defined by the polymeric layer and a pair ofsubstantially impervious sections (e.g. a polymeric side section),extending from one of the leg cuffs to sealingly engage the polymericlayer. In one embodiment, each leg cuff has an outer barrier layer andan inner barrier layer that is a portion of one of the substantiallyimpervious sidewalls. Moreover, the containment structure forms acontinuous and substantially impervious barrier (e.g., against coreleakage) around the core (i.e., except above the core wherein the wasteis received).

[0019] In yet another aspect of the invention, there is provided amethod of forming a breathable, stretchable section of a disposableabsorbent garment, such as a stretchable side panel or ear region. Themethod includes steps of selecting a first material for a first materiallayer (e.g., a topsheet non-woven material) and a second material (e.g.a backsheet nonwoven) for a second material layer, whereby the first andsecond material layers are bondable by an ultrasonic bonding process,and selecting an elastic material (e.g., an elastomer) for a stretchablematerial layer. The stretchable material layer is positioned between thefirst and second material layers to form a layer assembly, then one ormore bond sites on the layer assembly are targeted for bonding one ormore of the material layers together. The method then includes securingthe first, second, and stretchable layers together by ultrasonicallybonding the first material layer with the second material layer at theone or more sites. Accordingly, an aperture is formed through thestretchable material and the first material layer and the secondmaterial layer bond through the aperture, such that the apertureprovides a breathable passage therethrough. In a further variation, thetargeting step includes longitudinally and laterally spacing the bondsites so as to create a staggered pattern of breathable bond sites onthe stretchable section of the garment. This staggered pattern allowsfor maximum contracted (minimum relaxed) dimensions thus maximizing thefit range of the product.

[0020] A stretchable section is therefore made which provides improvedcomfort and functionality, among other attributes. The method may beemployed to form various sections of the garment including an earportion or waist portion.

[0021] It should again be noted that the invention is adaptable tovarious types of disposable absorbent garments including, but notlimited to, disposable diapers, training pants, adult incontinencegarments and other pull-on garments.

[0022] These and other objects, features and advantages of the presentinvention will become apparent to those skilled in the art from thefollowing detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]FIG. 1 is a perspective view of a disposable absorbent garmentaccording to one embodiment of the present invention shown as it wouldappear worn around the waist region of a user;

[0024]FIG. 2 is a top plan view of a composite web structure of adisposable absorbent garment shown unfolded and extended with portionscut away to reveal an underlying structure;

[0025]FIG. 3 is an exploded view of the disposable garment of FIG. 2;

[0026]FIG. 4 is a cross sectional view through line 4—4 in FIG. 2;

[0027]FIG. 5 is a cross sectional view of the garment in FIG. 4 shown ina relaxed, non-extended configuration;

[0028]FIG. 6 is a bottom plan view of a portion of a side waist regionof the garment in FIG. 4;

[0029]FIG. 6A is a close-up view of a portion in FIG. 6; and

[0030]FIG. 7 is a bottom plan view of a portion of a side waist regionin FIG. 4 shown in a contracted configuration.

DETAILED DESCRIPTION OF THE DRAWINGS

[0031]FIG. 1 depicts a disposable absorbent garment 10 embodying theinvention and in the form of a training pant or adult incontinencegarment. The garment 10 is formed with a waist opening 12 and two legopenings 14, and is shown, as it would appear worn about the lower torsoor waist region of a user. FIG. 2 depicts a composite web structure 10 aof the garment 10 in a flat and unfolded configuration, which it assumesduring one point in the manufacturing process when it is stretched inboth the lateral and longitudinal directions. As will be furtherexplained below, the web structure 10 a may be subsequently trimmed,folded, sealed, welded and/or otherwise manipulated to form a disposablegarment 10 in final form and for packaging. In this regard, thecomposite web structure 10 a is referred to as being finishable to forma disposable absorbent garment. In particular, the view of FIG. 2 isprovided to reveal with clarity most of the major elements of thedisposable absorbent garment 10 and/or web structure 10 a according tothe present invention.

[0032] It should first be noted that, upon review of the detaileddescription and the drawings provided herein, it will become apparent toone of ordinary skill in the art that the present invention is alsoapplicable to other disposable absorbent articles and, moreparticularly, to disposable absorbent garments other than training pantsand adult incontinence garments. The present invention is not intendedto be limited to the structures and processes specifically described andillustrated herein.

[0033] Referring to FIG. 2, the garment 10 features a layered assemblyor composite web structure 10 a that includes a liquid-permeable innerlayer or topsheet 16, a backsheet assembly including a hydrophobic andliquid permeable nonwoven backsheet 18 and a liquid-impermeable polyfilm barrier 60 and an absorbent core 36 disposed therebetween. The webstructure 10 a may be described further with reference to alongitudinally extending central axis A and a laterally or transverselyextending central axis B. Along the longitudinal axis A, the garment 10features a front waist region 20 having a front edge or frontlongitudinal end 52, a back waist region 22 having a back edge or backlongitudinal end 54, and a crotch region 24 extending between the frontwaist region 20 and the back waist region 22. Along the lateraldirection, the garment features left ear region 26 a, central bodyregion 28, and a right ear region 26 b. Similarly, the back waist region22 includes a left ear region 26 a, a central body region 28, and aright ear region 26 b. An elasticized leg cuff 38 extend between thefront waist region 20 and the back waist region 22 on either side of theabsorbent core 36. Described further below, the leg cuffs 38 or at leasta portion of the leg cuffs 38 are formed between the ear regions 26 a,26 b and the waist regions 20,22.

[0034] The web structure 10 a also has a longitudinal side edge 88 thatextends between each pair of ear regions 26 a, 26 b and is spaced oneach side of the absorbent core 36. As shown in FIG. 2, the side edges88 are not straight lines but includes curves which help form thegenerally hourglass shape of the composite web structure 10 a. Further,each of the ear regions 26 has a side edge area 30. During a later stagein the manufacturing process, the pair of ear regions 26 a are joinedtogether by mating their respective side edges 30 so as to form a sideseam 34 (see FIG. 1) and a leg opening 14. The ear regions 26 b aresimilarly joined to form a second side seam 34 and a second leg opening14, and also to form a waist opening 12. It should be understood thatthe pair of ear regions 26 a or 26 b may be joined together by employingprocedures well known to those skilled in the art (e.g., by ultrasonicwelding, thermal bonding, or use of an adhesive).

[0035] When the garment 10 is properly worn about the waist region ofthe user, the topsheet 16 (and leg cuffs 38) generally contacts thebuttocks of the user while the backsheet 18 faces outwardly from thebody of the user. Further, the front waist region 20 of the garment 10is situated at the front waist area of the user and the back waistregion 22 is situated at the back waist area of the user, while thecrotch region 24 is situated between the legs of the user and at thecrotch area. As for the ear regions 26, each pair of adjoined earregions 26 a, 26 b is designed to fit snugly about the side waist regionof the user with the side seams 34 positioned preferably in asubstantially vertical orientation.

[0036] As used herein for the purpose of description, each of the term“backsheet”, “backsheet assembly, or “outer layer of the garment” refersto any sheet, layer or composite that covers at least the core 36, butpreferably extends laterally beyond the core 36 toward the side edges 30and longitudinal side edges 88 of the garment 10 or web structure 10 a.Further, the term “backsheet”, “backsheet assembly” or “outer layer ofthe garment” may refer to any assembly, unitary or integrally, ofsheets, layers, or composites applied at least over the core 36, and anypart, portion, region or section thereof. For example, the backsheet mayhave applied thereon a film material and/or graphics. The backsheet andfilm material may be referred to as one structure or as individualstructures or layers.

[0037] The backsheet 18 may be constructed from a number of differentsuitable materials and, preferably, may have a breathable orvapor-permeable attribute (distinguishing it from liquid-permeable) sothat air can pass therethrough. In the embodiment of FIGS. 1-8, thegarment 10 (or web structure 10 a) is equipped with a “backsheet-polyassembly” comprising a backsheet material 18 of a hydrophobic,vapor-permeable, nonwoven material and a polyolefin film mask or filmbarrier 60 that is laminated or otherwise applied onto the backsheetmaterial 18 (see FIG. 3). In various embodiments, the film barrier 60may or may not be vapor-permeable. Preferably, the film barrier 60 maybe applied as a mask or sheet in a central area of the web structure 10a, as shown in FIG. 3. The film barrier 60 has an overall width that isless than the width of the other backsheet materials but sufficientlywide to cover the absorbent core 36.

[0038] One suitable construction for the backsheet assembly 18 includesan outer layer of spunbond polypropylene fiber with a basis weight ofabout 15 gsm (available from BBA Nonwovens, of Simpsonville, S.C.) and apolyethylene film of about 0.5 mil (0.0005″) thickness adhesivelylaminated to the outer layer. Such a polyethylene film is availablefrom, and manufactured by, Exxon Chemical USA, of Houston, Tex. The filmmay be laminated using adhesive available from National Starch &Chemical Company of Bridgewater, N.J. Yet another suitable constructionfor the backsheet 18 includes a web of spunbond or SMS(spunbond\meltblown\spunbond) nonwoven material and breathable ornon-breathable films of 0.5 mils to 2.0 mils in thickness.

[0039] As shown in FIG. 3, the backsheet 18 is a sheet that provides theouter layer of each of the ear regions 26 as well as the outer layer ofthe rest of the front and back regions 20, 22 and the crotch region 24.Thus, the outer layer of each ear region 26 may be referred to as beingunitary with, and forming a lateral extension of, the rest of thebacksheet material. The backsheet 18 therefore extends up to and forms,at least partially, a side edge of the ear regions 26 and the webstructure 10 a.

[0040] In an alternative embodiment, the backsheet 26 may include acentral section and a pair of left and right side panels or sheets whichare distinct from the central section. Each of the side panels is joinedto and, thereby, integrated with the central section. The left sidepanel extends between each of the left ear regions 26 a and provides anouter layer common to both ear regions 26 a. Similarly, the right sidepanel extends between each of the right ear regions 26 b and provides anouter layer common to both right ear regions 26 b. In yet anotherembodiment, the backsheet 18 includes, in addition to a central section,four separate side panels: a front right ear panel, a back right earpanel, a front left panel, and a back left panel. Each of the panelsforms an outer layer of an ear region 26 and is joined to, andintegrated with, the central section of the backsheet 18.

[0041] The absorbent core 36 is generally elongated and rectangular inshape. As best shown in FIG. 2, the core 36 is generally centered aboutthe longitudinal axis A and laterals axis B of the garment 10, andfirmly secured between the topsheet 16 and backsheet 18. The core 36 ispreferably made of an absorbent composition adapted to absorb bodilyliquids received through the topsheet 16. Typically, the absorbentcomposition includes a fluffed wood pulp component for wicking andstructural integrity and a high absorbency material (or super absorbent)for containing liquids. However, the garment 10, according to thepresent invention, is equally adapted to utilize absorbent cores ofvarying shapes and compositions, as well as other types of cores knownin the art.

[0042] As used herein for purposes of description, the term “topsheet”,“topsheet assembly” or “inner layer of the garment” may refer to anysheet, layer or composite that covers at least the core 36, butpreferably extends beyond the core 36 toward the side edges 30 andlongitudinal side edges 88 of the garment 10 or web structure 10 a.Further, the term “topsheet”, “topsheet assembly” or “inner layer of thegarment” refers to any assembly, unitary or integrally, of sheets,layers, or composites applied at least over the core 36, and any part,portion, region or section thereof.

[0043] The topsheet 16 may be constructed from a wide range of suitablematerials including nonwoven webs of natural fibers (e.g., wood orcotton) or synthetic fibers (e.g., polypropylene or polyester), acombination of such webs or fibers, or apertured film. One suitabletopsheet material is a 15 gsm spunbond polypropylene from Avgol NonwovenFabrics of Holon, Israel. In addition, the topsheet 16 may be treatedwith a surfactant to facilitate liquid transfer, especially at a centralzone of the topsheet 16 over the core 36, and an inner surface of thetopsheet 16 may be treated with a chemical to increase the surfacetension of liquid passing through the material.

[0044] Referring to the web structure 10 a of FIG. 3 and also FIG. 4,the topsheet 16 may be formed from a three-piece structure including acenter section 16 a disposed above (but not necessarily directly above)the absorbent core 36 and two lateral side sections 16 b each laterallyextending from the center section 16 a. The lateral end or edge sections88 of the lateral side sections 16 b form the lateral ends or edges 88of the web structure 10 a (and of the ear portions 26). Referring toFIG. 4, the proximal end or edge sections of lateral side sections 16 bare turned upwardly and provide an inwardly folded edge 90. Theseproximal edge sections 90 form an outer layer or outer cuff section 38 bof leg cuff 38 that is joined with a substantially hydrophobic andimpervious inside (or inner) layer or inside cuff section 38 a of theleg cuff 38.

[0045] The inside cuff section 38 a is preferably formed from asubstantially hydrophobic and impervious material substantially similarto or the same as the polymeric material from which the film barrier 60is made. Referring to the cross sectional view of FIG. 4, the insidecuff section 38 a extends downwardly from the folded edge so as toengage an outer edge of center section 16 a (near the top of the core36) and, then, further downwardly to engage the film barrier 60 (near orbelow the bottom of the core 36). The inside cuff section 38 a of theleg cuffs 38 may engage each of the outer edge of the central section 16a of the topsheet 16 and the film barrier 60 by adhesive or weldingmeans and other joining means. Since the film barrier 60 and the insidecuff section 38 a can be formed from the same substantially hydrophobicand impervious material, these two components may be easily integratedas one piece or applied as one piece in the manufacturing process.

[0046] Further, because the inside cuffsections 38 a are connected to,integrated with or otherwise sealingly engages the film barrier 60, acontinuous and substantially hydrophobic and impervious “bathtub-like”containment structure or barrier is formed under and on both sides ofthe absorbent core 36. The bottom and side walls of this bathtub-likecontainment structure is provided by the film barrier 60 and the pair ofinside cuff sections 38 a respectively. Accordingly, the inventivegarment 10 features a unique containment structure that significantlyreduces the possibility of leakage from the core area of the garment 10.In particular, the engagement of the side wall or inside cuff section 38a with the bottom or film barrier 60 of the bathtub-like containmentstructure prevents migration of waste (from the area of the core 36)underneath the cuff 38 toward the sides of the garment 10.

[0047] The leg cuffs 38 are preferably positioned on either side of orspaced from longitudinal axis A and outboard of the core 36, and extendsgenerally upwardly from the topsheet 16 (i.e., toward the user). Thelongitudinal ends of the cuffs 38 may be attached, for example, to thetopsheet 16 in the front and rear waist regions 20, 22. Preferably, theends of the leg cuffs 38 are tacked down inwardly and attached, forexample, by adhesive, to the web structure 10 a. Such a constructionbiases the cuff 38 inwardly and is generally considered to cause thecuff 38 to exhibit improved leakage prevention properties.

[0048] Preferably, the leg cuffs 38 are equipped with one or moreelastic material layers or members 40, which extend along a substantiallength of the leg cuffs 38. In a common application, the elastic members40 are placed within or underneath the leg cuffs 38 while in a stretchedcondition and then glued to the cuff at least at their ends. Whenreleased or otherwise allowed to relax, the elastic members 40 retractinwardly. When the garment 10 is worn, the elastic members 40 functionto contract the leg cuffs 38 about the buttocks of the user in a manner,which effects a seal between the garment 10, and the buttocks.

[0049] The leg cuffs 38 (or at least the outer cuff section 38 b) may beformed by a number of alternative methods known in the art. One methodinvolves gluing a separately constructed leg cuff or cuff section to thetop surface of the web structure 10 a. Another method requires formingthe leg cuff or cuff section from the topsheet or the backsheet 18. Yetanother method involves creating and folding noodle cuffs as disclosedin U.S. Pat. No. 5,536,350, which is hereby incorporated by reference.

[0050] In an alternative embodiment of the invention, a longitudinallystretchable leg gather is positioned proximately each longitudinal sideedge 88. When the garment 10 is properly worn by the user, each leggather encircles a leg of the user and effects a seal thereon to preventleakage. Generally, the leg gather is formed with elastic members whichare typically applied in the stretched or extended condition and areplaced between the topsheet 16 and backsheet 18. The elastic members areglued or otherwise secured to one or both of the topsheet 16 orbacksheet 18, or other material layer of the web structure 110 a. Uponrelease from its stretched condition, the elastic members retract withthe attached material layer and form gathered leg regions.

[0051] The present invention is adapted to use other leg gatherconstructions known in the art. Moreover, the present invention mayutilize leg gathers in combination with leg cuffs 38 as described aboveor, alternatively, alone without leg cuffs.

[0052] As best shown in FIGS. 2 and 3, the web structure 10 a and thus,the disposable absorbent garment 10, preferably includes, disposedbetween the central section 16 a and core 36, an acquisition layer 48and top tissue layer 47. The acquisition layer 48 (or surge layer) ispreferably situated between the topsheet 16 and the core 36. Onefunction provided by such an acquisition layer 48 is to spread out ordispense liquid flow received by the garment 10 so that liquid isdistributed more evenly over the surface of the core 36. By slowing downthe liquid flow, the core 36 has sufficient time to absorb the liquidreceived thereon. The acquisition layer 48 also serves to prevent thesituation wherein the core 36 is saturated locally, while a substantialremainder of the core 36 is not absorbing liquid.

[0053] Therefore, FIG. 3 provides a cross-sectional view which depictsthe various layers of the web structure 10 a and the respectivestructural relationships of the layers. In further embodiments, theinventive garment 10 may utilize a multi-purpose material as one of thelayers. Such a multi-purpose material would then provide multiplefunctions, thereby eliminating the need for one or more of theabove-described layers.

[0054] As best shown in FIGS. 2 and 3, the web structure 10 a and thus,the disposable absorbent garment 10, is also equipped with an elasticwaist band 44 that is inserted between the topsheet 16 and backsheet 18and adjacent the central body regions 28 of each of the front waistregion 20 and back waist region 22. In other forms of the invention, thewaist band 44 may be omitted or may be extended substantiallycontinuously along the top end of the front waist region 20 and backwaist region 22, thereby encircling or partially encircling the waist ofthe user when the garment 10 is worn. The waistband 44 is preferablymade of an open cell urethane foam materials available from GeneralFoam, of Paramus, N.J.

[0055] Still referring to FIGS. 2 and 3, the web structure 10 a ofdisposable absorbent garment 10 is further equipped with a stretchablematerial layer or member 46 (e.g., an elastic member) substantiallyincorporated with, and made a part of, one or more of the ear regions26. As best shown in FIG. 3, the stretchable member 46 is preferablyinterposed between the topsheet 16 and backsheet 18 in the ear regions26. The stretchable member 46 extends longitudinally from nearlyadjacent a longitudinal end 52 towards the crotch portion 24 (i.e.,about 5-6″ long) and laterally from substantially proximate the centralbody portion 28 toward the side edge area 30. However, the stretchablemember 46 should be spaced sufficiently inwardly from the side edge area30 so as not to be affected by or to affect the attachment of the sideedges 30 to one another to form the garment 10. Furthermore, the presentinvention is not limited to specifically sized or positioned stretchablemembers 46. Instead, the stretchable member 46 may assume a variety ofshapes and sizes and may be positioned at various locations within theear regions 26 as long as the stretchable member 46 provides the earregions 26 with sufficient extensibility to accomplish joinder of theear regions 26 to form a waist region.

[0056] When the ear regions 26 are joined by the welding/bondingprocess, there is formed an absorbent garment 10 having stretchable sidewaist regions formed by the pairs of ear regions 26 a, 26 b. Thestretchable member 46 is designed and is positioned within the earregions 26 to facilitate stretching of the ear regions 26 in the lateraldirection. The garment 10, therefore, can extend around and contracttoward the side waist region of the user, and effect a snug fit. In onealternative embodiment of the invention, a substantially continuouselongated stretchable member 46 is positioned along both the front waistregion 22 and back waist region 20, thereby acting as a nearlycontinuous belt around the user. The continuity of the belt isinterrupted only by the side seams 34. In such an embodiment of theinvention, the foam waistband 44 is preferably eliminated.

[0057] In a unique aspect of the invention, the ear regions 26 areattached to the stretchable member 46 when the stretchable member 26 isin a stretched or extended configuration. In forming an ear region 26,the stretchable member 46 is first extended or otherwise stretchedlaterally and then the inside surface of the topsheet material and/orbacksheet material at the ear region 26 is\are secured or otherwiseattached to a corresponding surface of the stretchable member 46 byconventional adhesive or mechanical means. It is important to extend thesheet material(s) to an extent where it displays a smooth, flat outersurface, but not necessarily to the extent where the material stretchesand/or deforms. When the stretchable number 46 is then allowed tocontract or relax, the topsheet material and/or backsheet materialcontracts with it.

[0058] To illustrate, FIG. 4 depicts the ear region 26 having an outerlayer provided by the single-sheet backsheet material and formed unitarywith the rest of the backsheet 18, and an inner layer provided by theleg cuff lateral section 16 b of the topsheet 16. The ear region 26 isshown immediately after a section of both the lateral section 16 b andthe backsheet 18 are attached to the stretchable member 46 (and alsowhen the garment 10 is worn by the user). In this view, the stretchablemember 46 is maintained in the stretched or extended configuration, andthe top lateral section 16 b and backsheet 18 each display flat, smoothouter surfaces 90, 92 respectively. FIG. 5 depicts the ear region 26after the stretchable member 46 is released and allowed to contractlaterally to a relaxed, contracted or unscratched configuration.Preferably, the stretchable member 46 contracts from an initial width ofabout 4½″ to 5½″ to a relaxed or contracted width of about 2″ to 3″. Thelayered composite or assembly that is formed by the leg cuff lateralsections 16 b, backsheet 18 and stretchable member 46 is moved inwardlytoward the leg cuff 38 and, as a result, the lateral width of thegarment 10 is reduced (e.g., from about 15″ to 16″ across to about 11″to 12″ across). Moreover, the outer surface 90 of the lateral section 16b and the outer surface 92 of the backsheet 18 are slacked and formwrinkles and undulations on both sides of the stretchable member 46(i.e., exhibit gathers).

[0059] To further illustrate, the bottom plan view of FIG. 6 is providedto show the condition of the backsheet 18 when the stretchable member 46(and the stretchable ear portion 26) is disposed in an extended orstretched configuration (e.g., when the garment 10 is worn by the user).In the extended configuration, the backsheet 18 displays a smooth,continuous outer surface 92. Thus, when the garment 10 is worn aroundthe waist of the user, the front and back waist regions 20, 22 togetherdisplay a continuous, smooth outer surface substantially all around thewaist of the user except where it is interrupted by the side seams 34.Conversely, FIG. 7 is a bottom plan view showing the condition of thebacksheet 18 when the stretchable member 46 is disposed in thecontracted or unstretched condition (e.g., when the garment 10 is notbeing worn by the user). In this view, wrinkles and a series ofundulations (i.e., exhibits gathers), characterize the outer surface 92of the backsheet 18 at the ear region 26.

[0060] It should be further noted that neither the side section 16 b northe backsheet 18 is permanently elongated during the forming of thecomposite layer, or during normal subsequent wear. In other words, thetopsheet 16 and backsheet 18 are not stretched beyond its elasticregion, and in some processes are merely extended to smooth out theouter surface, but not stretched beyond that point. In summary, thetopsheet 16 (i.e., top cuff 16 b) and backsheet 18 are merely stretchedor extended to form flat, smooth surfaces 90, 92 during manufacturingand when the garment 10 is worn about the user, but retracts to awrinkled, contracted state when the garment 10 is otherwise not worn.

[0061] The stretchable member 46 may be formed from an elastic material,such as the material typically used for the elastic waistband 44, or anyother material with the appropriate stretch and return properties. Thestretchable member 46 may be also formed from a heat-activatedelastomeric material or elastomer that is elasticized upon initialapplication of a pre-determined amount of heat. The heat-activatedelastic also contracts from an extended configuration to a contractedcondition upon the initial application of heat in the vicinity of thestretchable member 46. In a process which makes use of theheat-activated elastomer, sections of the topsheet 16 and backsheet 18are fastened to opposite surfaces of a stretchable member 46incorporating the heat-activated elastomer and then contract with thestretchable member 46 upon the initial application of heat to theelastic. The stretchable member 44 incorporating the heat-activatedelastomer may stretch or extend laterally when the garment 10 is wornaround the waist of the user and then retract to its contracted, relaxedor unscratched configuration when the garment 10 is not being worn.Further, the materials of the leg cuff lateral section 16 b and thebacksheet 18 can extend laterally with the stretchable member 46 todisplay flat, smooth outer surfaces 90, 92 at the ear regions 26 andthen contract with the stretchable member to display outer surfaces 90,92 characterized by wrinkles and a series of undulations, and exhibitinggathers.

[0062] Preferably, the stretchable member 46 is applied by firstextending or stretching the stretchable member 46 laterally and thensecuring (or otherwise attaching) the inside surface of the topsheetmaterial and/or backsheet material to the corresponding surface of thestretchable member 46 (which is in the stretched condition). This latterprocedure may be implemented by a mechanical thermal bonding processsuch as ultrasonic or heat and pressure bonding practices, and, morepreferably, by ultrasonic bonding process.

[0063] In any of the above bonding processes, the topsheet 16 ismechanically bonded to the backsheet 18 at localized bond sites or bondpoints 100, at which the topsheet 16 and backsheet 18 are joinedtogether through the stretchable member 46 (see FIGS. 6 and 7).Preferably, an ultrasonic bonding process is employed to bond thetopsheet 16 and the backsheet 18, through the stretchable member 46.Employment of this bonding process, creates holes or apertures at thebond sites 100 and through the stretchable member 46. These holes orapertures at the bond sites 100 provide breathability or airpermeability to the ear regions 26 a,26 b (see also FIG. 6). Moreparticularly, the holes at the bond sites 100 are created as a result ofthe selection of materials for the topsheet 16, backsheet 18 andstretchable member 46, and use of the ultrasonic bonding process. Inthis process, the non-woven materials (i.e., topsheet 16 and backsheet18) requires substantially more energy to bond than the materialselected for the elastic member 46 (i.e., a polymeric material).Accordingly, the level of ultrasonic bonding that is sufficient to bondthe non-woven materials also causes the material for the elastic member46 to fracture and/or disintegrate. As a result, the two non-wovenlayers bond together, but trap the polymeric material of the elasticmember 46 therewith. Further, the hole that is blown or created throughthe elastic member 46 is larger than the bond site, and the twonon-woven layers bond with each other through the center of the hole.

[0064] Furthermore, the inventive garment and manufacturing processprovide a pattern for placement of the bond sites 100 on the ear region26 a,26 b. The preferred pattern is a staggered pattern as shown in FIG.6 which maximizes the spacing between bond sites 100 for a given numberof bond sites 100. Importantly, the spacing between consecutive bondsites along direction of stretching (i.e., lateral direction) ismaximized such that the elasticity of the ear region in this directionis not significantly altered nor compromised. A breathable ear region orside panel is, therefore, provided having adequate elastic propertiesand contracting force.

[0065] Although, the bond sites or holes may be formed in any shape, itis preferred to select a shape that is particularly adapted tostaggering, such as the rectangular shape shown in FIG. 6. Such a shape,wherein the longitudinal dimension is significantly greater than thelateral dimension, provides a larger capacity for stretching in thelateral direction while minimizing the potential for propagating tears.

[0066] It is understood that it will be apparent to one skilled in theart, upon reading the detailed descriptions provided herein and viewingthe accompanying Figures, to employ various conventional manufacturingelements (e.g., rollers, conveyors, etc.) and arrangements thereof toproduce the garment and more particularly, a breathable, stretchablesection of the garment as described above. Such manufacturing elementsinclude those described and illustrated in pending application Ser. No.09/215,473, entitled “Disposable Absorbent Garment Having StretchableSide Regions.” This application and invention are also assigned to theassignee of the present invention (hereby incorporated by reference).

[0067] The above-described inventive garment is particularly adapted fora method of manufacturing in which a web structure is advanced in the“in-line” or “machine” direction. The terms “in-line direction”, “inprocess direction”, and “machine direction” are used herein to refer toan orientation and travel of the composite web structure during themanufacturing process. When oriented in the “inline”, “in process” or“machine” direction, the front or back waist regions is positioned aheadof the crotch region in the direction of conveyor travel with the otherwaist regions directly trailing the crotch region. This is differentfrom the cross-machine orientation wherein the web structure is turned90 degrees from the in-line or machine direction such that the crotchregion and the waist regions are aligned along a lateral line that isnormal to the direction of conveyor travel.

[0068] The manufacturing method may be regarded as beginning with thedelivery of a continuous web structure comprising of an absorbent core,top tissue and acquisition layer (e.g., core assembly). Typically, theabsorbent core is received from a drum former, delivered to a transferroll and then onto a surface of a main conveyor. Each absorbent core ispositioned on the conveyor such that its length is generally parallel tothe machine direction.

[0069] The method further includes the use of a supply roll tocontinuously apply or otherwise provide the top tissue layer onto eachabsorbent core. Downstream of the supply roll, another supply roll and acut and slip unit are situated. These units are conventional types whichare readily available to one skilled in the art. The supply rolldelivers the acquisition layer material to the cut and unit to formindividual patches of the material which are spaced apart and thenapplied on top of the top tissue. This step therefor provides anacquisition layer on the composite web structure. A continuous webstructure is thereby formed comprising absorbent core, top tissue andacquisition layer and is oriented in the in-line direction.

[0070] Next, this continuous web is moved toward the pad knife orcutting roll which is used to cut the composite web structure laterallybetween the absorbent core. Accordingly, this cutting step provides aplurality of individual, in-line composite web structures comprisingabsorbent core covered with top tissue and acquisition layer. A supplyroll positioned downstream of the pad knife such that, as each webstructure is conveyed thereto, a polymeric layer is applied or providedonto the bottom of the absorbent core. Application of the polymericlayer forms the film barrier layer beneath the absorbent core.

[0071] Upon or simultaneous with the step of applying the film barrierlayer is the step of applying a three-piece topsheet assembly equippedwith poly-on, elasticized leg cuffs onto the web structure. A compositestructure including this topsheet assembly maybe constructed in aseparate process or subprocess before it is delivered to the mainconveyer and applied to the top of the composite web structure.

[0072] When the composite web structure including the three-piecetopsheet having poly-lined leg cuff is attached to the web structure,the polyliner is joined with or otherwise engages opposite side edges ofthe barrier film. This engagement between the two substantiallyhydrophobic and impervious layers results in the bathtub-likecontainment structure disposed at least adjacent the bottom and sides ofthe core.

[0073] In what may be regarded as the next stage of the process, a webstructure including backsheet and stretchable members is then applied tothe composite web structure. This web structure may be constructed froma subprocess employing a subsystem which is separate from but convergesonto the main conveyor. At the conveyor, the web structure is applied tothe bottom of the composite web structure so as to form a laminationtherewith.

[0074] A stretched ear region or side panel is, therefore, created thatis made up of an elastomeric film laminated between the full widthbacksheet and the full width topsheet. In this respect, an elastic sidepanel or ear region becomes an integral part of the complete absorbentgarment. Adhesive may be applied on the backsheet material and/or thestretchable member prior to these two elements coming into pressurizedcontact.

[0075] In a subsequent step in the process, the web structure isconveyed to a thermal-bonding module (e.g. employing ultrasonic or heatand pressure bonding practices). At the module, the composite webs 50,49 are bonded together and through the stretchable member to form a sidewaist region. As described previously, energy from the preferred bondingprocess creates a hole in the stretchable member and allows for thetopsheet material and the backsheet material to bond therethrough. Thisalso creates a vent at the bond site through which air may pass.

[0076] After the bonding process, the resulting composite web may beheld under vacuum and passed through a die cut station wherein the legopenings are cut out from each of the lateral sections and thecorresponding section of the backsheet. Then, the continuous compositeweb structure is cut at a knife station to form individual webstructures. Each web structure is subsequently folded and then passedthrough a seam welding station where side edge areas of the ear regionsare joined together by any suitable method of bonding, includingultrasonic, thermal or adhesive bonding. The folded and seamed compositeweb structure which, at this point, constitutes an individual absorbentgarment is passed through a side panel tuck station where the side panelof the garment is folded between the front and back side panels beforebeing delivered to a stacker.

[0077] For clarity, some subprocesses such as the application of waistelastic members and leg gathers to the web structure 10 a are described.It should be understood, however, that the present invention is adaptedto incorporating various constructions of these components and suitablemethods of applying such constructions onto a composite web structure.

[0078] It should be noted that the web structure 10 a and the componentsthat make up the web structure are positioned in the in-line or machinedirection C during the preferred manufacturing process (i.e., whereinthe longitudinal axis A is coincidental with the direction of webtravel). Applicant believes that positioning the web structure 10 a inthis manner furthers efficiency in the manufacturing process andpromotes quality in the final product. In one aspect of the invention,the design of the web structure 10 a and the garment 10, particularlythe use of the stretchable member 46 instead of elongated elasticsthreads which are directed laterally across the width of the garment 10,allows for such an in-line process of manufacturing to be employed.

[0079] Although several embodiments of the present invention have beenshown or described, alternate embodiments will be apparent to thoseskilled in the art and are within the scope of the present invention.Therefore, the invention is to be limited only by the claims.

What is claimed is:
 1. A disposable absorbent garment, comprising: atopsheet; a backsheet; and an absorbent core disposed between saidtopsheet and said backsheet, wherein said topsheet, said backsheet, andsaid core together form a front region, a back region, and a crotchregion disposed between said front region and said back region, andwherein a vertical longitudinal plane extends substantially centrallythrough said front, back, and crotch regions; and wherein each of saidfront and back regions includes a pair of ear portions extending insubstantially opposite lateral directions with respect to saidlongitudinal plane, each of said ear portions being a breathable,stretchable layer assembly.
 2. The garment of claim 1, wherein each ofsaid ear portions includes: an outer material layer that is an extensionof said backsheet, said outer material layer extending laterally up to alateral edge of said ear portion; an inner material layer that is anextension of said topsheet, said inner layer extending laterally up to alateral edge of said ear portion; and a stretchable material layersecured between said inner layer and said outer layer.
 3. The garment ofclaim 1, wherein said topsheet consists of: a central section includinga portion generally disposed over the core, and a pair of side sections,each said side section forming said inner layers of two of said earportions and being separate from said central section.
 4. The garment ofclaim 1, wherein said stretchable layer assembly of each said earportion includes a plurality of vent sites.
 5. The garment of claim 4,wherein said stretchable layer assembly includes an inner materiallayer, an outer material layer and a stretchable material layer disposedtherebetween and wherein, at said vent sites, said outer material layeris bonded to said inner material layer.
 6. The garment of claim 5,wherein, at said vent sites, said outer layer and said inner layer arebonded by ultrasonic bonding, thereby forming a breathable passagethrough said stretchable material layer.
 7. The garment of claim 4,wherein said vent sites are spaced laterally and longitudinally from oneanother so as to form a staggered pattern on said ear portion.
 8. Thegarment of claim 1, further comprising a pair of longitudinallyextending leg cuffs, each leg cuff being spaced in general parallelrelation to a lateral side of said core, said leg cuff having, at least,a first layer and a second layer, said first layer being formed from asubstantially impervious material and said second layer being formedfrom said topsheet.
 9. The garment of claim 8, further comprising apolymeric layer disposed generally beneath said core, said first layerof said leg cuff being part of a polymeric side section extending fromsaid leg cuff to sealingly engage said polymeric layer.
 10. The garmentof claim 9, wherein said side section and said polymeric layer form asubstantially impervious containment structure extending continuouslyfrom adjacent one lateral side of said core to an opposite lateral sideof said core.
 11. The garment of claim 1, wherein said stretchable layerassembly of said ear portion includes an inner material layer, an outermaterial layer, and a stretchable material layer disposed therebetween,said stretchable material layer being extendible between a contractedconfiguration and an extended configuration, and said stretchablematerial layer being secured to said outer layer when said stretchablematerial layer is disposed in an extended configuration such that saidouter material layer is subsequently contractible then extendible withsaid stretchable material layer.
 12. A disposable absorbent garment,comprising: a topsheet; a backsheet; and an absorbent core disposedbetween said topsheet and said backsheet, wherein said topsheet, saidbacksheet, and said absorbent core form a front region, a back region,and a crotch region disposed between said front region and said backregion, and wherein a longitudinal plane extends substantially centrallythrough said, front, back and crotch regions; wherein each of said frontand back regions includes a pair of ear portions extending insubstantially opposite lateral directions with respect to saidlongitudinal plane, and wherein each said ear portion includes astretchable layer assembly having, an outer material layer that is anextension of said backsheet, said outer material layer extendinglaterally to form, at least partially, a side edge of said ear portion,an inner layer that is an extension of said topsheet, said inner layerextending laterally to form, at least partially, a side edge of said earportion, and a stretchable material layer secured between said innerlayer and said outer layer.
 13. The garment of claim 12, wherein saidtopsheet consists of: a central section including a portion generallydisposed over the core, and a pair of side sections, each said sidesection forming said inner layers of two of said ear portions, each saidside section being separate from said central section.
 14. The garmentof claim 12, wherein each said ear portion is a breathable layerassembly having a plurality of vent sites.
 15. The garment of claim 14,wherein, at each said vent site, said outer layer is ultrasonicallybonded to said inner layer to form a breathable passage through saidstretchable material layer.
 16. The garment of claim 14, wherein saidvent sites are spaced laterally and longitudinally from one another soas to form a staggered pattern on said ear portion.
 17. The garment ofclaim 12, further comprising a longitudinally extending leg cuff spaced,in generally parallel relation to a lateral side of said core, said legcuff having at least a first layer and a second layer, said first layerbeing formed from a substantially impervious material and said secondlayer being formed from said topsheet.
 18. The garment of claim 17,further comprising a polymeric layer disposed generally below said core,said first layer being formed from a polymeric material and extendingfrom said leg cuff to sealingly engage said polymeric layer.
 19. Thegarment of claim 1, wherein said topsheet and said backsheet extend tosaid side edge of said ear portion to form a seamless stretchable earportion.
 20. The garment of claim 12, wherein said stretchable materiallayer is an elastic material that is extendible from a contractedconfiguration to an extended configuration, said stretchable materiallayer being secured to said outer layer when said stretchable materiallayer is disposed in an extended configuration such that said outermaterial layer is subsequently contractible then extendible with saidstretchable material layer.
 21. A disposable absorbent garment,comprising: a topsheet; a backsheet; an absorbent core disposed betweensaid topsheet and said backsheet, wherein said topsheet, said backsheet,and said absorbent core form a front region, a back region, and a crotchregion disposed between said front region and said back region, andwherein a vertical longitudinal plane extends substantially centrallythrough said front, back, and crotch regions; wherein each of said frontand back regions includes a pair of ear portions extending insubstantially opposite lateral directions with respect to saidlongitudinal plane; and a pair of longitudinally extending leg cuffsspaced in generally parallel relation from a lateral side of said core,each said leg cuff having a first layer and a second layer, said firstlayer being formed from a substantially impervious material and saidsecond layer being formed from said topsheet.
 22. The garment of claim21, wherein each of said front and back regions includes a pair of earportions extending in substantially opposite lateral directions withrespect to said longitudinal plane, each of said ear portions being astretchable layer assembly including an outer material layer, an innermaterial layer, and stretchable material layer secured therebetween. 23.The garment of claim 22, wherein said outer material layer is anextension of said backsheet, said outer material layer extendinglaterally to form, at least partially, a side edge of said ear portion,and wherein said inner material layer is an extension of said topsheet,said inner layer extending laterally to form, at least partially, a sideedge of said ear portion.
 24. The garment of claim 21, wherein saidtopsheet consists of: a central section including a portion generallydisposed over the core, and a pair of side sections, each said sidesection forming said inner material layers of two of said ear portionsand being separate from said central section.
 25. The garment of claim21, wherein said stretchable layer assembly is a breathable layerassembly including a plurality of vent sites.
 26. The garment of claim25, wherein, at said vent sites, said outer layer is ultrasonicallybonded to said inner layer to form a breathable passage through saidstretchable material layer.
 27. The garment of claim 25, wherein saidvent sites are spaced laterally and longitudinally from one another soas to form a staggered pattern on said ear portion.
 28. The garment ofclaim 21, further comprising a polymeric layer disposed generallybeneath said core, each of said first layers of said leg cuffs beingformed from a polymeric sidewall extending from said leg cuff tosealingly engage said polymeric layer.
 29. The garment of claim 28,wherein said sidewalls and said polymeric layer form a substantiallyimpervious barrier extending continuously from adjacent one lateral sideof said core to an opposite lateral side of said core.
 30. The garmentof claim 22, wherein said stretchable layer assembly of said ear portionincludes an inner material layer, an outer material layer, and astretchable material layer disposed therebetween, said stretchablematerial layer being extendible between a contracted configuration andan extended configuration, and said stretchable material layer beingsecured to said outer material layer when said stretchable materiallayer is disposed in an extended configuration such that said outermaterial layer is subsequently contractible then extendible with saidstretchable material layer.
 31. A disposable absorbent garment,comprising: a topsheet; a backsheet; an absorbent core disposed betweensaid topsheet and said backsheet; a polymeric layer disposed adjacentsaid backsheet, wherein said topsheet, said backsheet, said polymericlayer, and said absorbent core together form a front region, a backregion, and a crotch region disposed between said front region and saidback region, and wherein a longitudinal plane extends substantiallycentrally through said, front, back and crotch regions; wherein each ofsaid front and back regions includes at least a pair of ear portionsextending in substantially opposite lateral directions with respect tosaid longitudinal plane; a pair of longitudinally extending leg cuffs,each said leg cuff being spaced in generally parallel relation from alateral side of said core; and a pair of side containment sections eachextending from one of said leg cuffs to sealingly engage said polymericlayer, so as to form, with said polymeric layer, a substantiallyimpervious containment structure about said core.
 32. The garment ofclaim 31, wherein each of said leg cuffs has as an outer layer and aninner layer, said inner layer being a portion of one of said sidecontainment sections.
 33. The garment of claim 32, wherein said innerlayer is formed from a polymeric material.
 34. The garment of claim 32,wherein said side containment sections and said polymeric layer form abarrier extending continuously from adjacent one lateral side of saidcore to an opposite lateral side of said core.
 35. The garment of claim32, wherein each of said ear portions is a stretchable layer assemblyincluding an outer material layer that is an extension of saidbacksheet, said outer material layer extending laterally to form, atleast partially, a side edge of said ear portion, an inner materiallayer that-is an extension of said topsheet, said inner material layerextending laterally to form, at least partially, a side edge of said earportion, and a stretchable material layer secured between said innermaterial layer and said outer material layer, said stretchable materiallayer being extendible between a contracted configuration and anextended configuration, and said stretchable material layer beingsecured to said outer material layer when said stretchable materiallayer is disposed in an extended configuration such that said outermaterial layer is subsequently contractible then extendible with saidstretchable material layer and returnable to substantially smooth andplanar configuration.
 36. The garment of claim 32, wherein said topsheetconsists of: a central section including a portion generally disposedover the core, and a pair of side topsheet sections, said side topsheetsection forming said inner material layers of two of said ear portionsand said outer layer of said leg cuff, and wherein each said sidetopsheet section is separate from said central section.
 37. The garmentof claim 31, wherein said stretchable layer assembly is breathable layerassembly including an inner material layer, an outer material layer anda stretchable material layer disposed therebetween, said layer assemblyhaving plurality of vent sites wherein, at said vent sites, said outermaterial layer is ultrasonically bonded to said inner layer to create abreathable passage through said stretchable material layer and whereinsaid vent sites are spaced laterally and longitudinally from one anotherso as to form a staggered pattern on said ear portion.
 38. A method offorming a breathable, stretchable section of a disposable absorbentgarment, said method comprising the steps of: selecting a first materialfor a first material layer and a second material for a second materiallayer, whereby said first and second material layers are bondable by anultrasonic bonding process; selecting an elastic material for astretchable material layer; positioning the stretchable material layerbetween the first and second material layers to form a layer assembly;targeting one or more bond sites on the layer assembly for bonding oneor more of the material layers together; and securing the first, second,and stretchable layers together by ultrasonically bonding the firstmaterial layer with the second material layer at the one or more sites,whereby an aperture is formed through the stretchable material andwhereby the first material layer and the second material layer bondthrough the aperture, and such that the aperture provides a breathablepassage therethrough.
 39. The method of claim 38, wherein the step ofselecting the first and second material includes selecting a topsheetmaterial and a backsheet material layer, respectively.
 40. The method ofclaim 38, wherein the step of selecting the first and second materialincludes selecting a first non-woven material and a second non-wovenmaterial, respectively.
 41. The method of claim 38, further comprisingthe step of stretching the stretchable material layer to an extendedconfiguration and performing the securing step when the stretchablematerial layer is in the extended configuration such that the first andsecond material layers are subsequently contractible and then extendiblewith the stretchable material layer.
 42. The method of claim 38, whereinthe targeting step includes longitudinally and laterally spacing thebond sites so as to create a staggered pattern of breathable bond siteson the stretchable section of the garment.
 43. The method of claim 38,wherein the steps of selecting the first and second materials and thepositioning step includes positioning the first, second, and stretchablematerial layers so as to form a stretchable side waist region of thegarment after the securing step.